Thermal spray coated reinforced polymer composites

Abstract

Forming and depositing a high temperature inorganic coating on a polymeric composite substrate surfaces having deposited thereon an interlayer, and articles produce therefrom. Methods of providing functional properties to said composites are also disclosed.

What is claimed: 
     
       1. A composite comprising:
 a substrate comprising a reinforced organic polymer matrix, the substrate having a substrate surface; 
 at least one interlayer of silicon oxycarbide on the substrate surface, the interlayer having a thickness extending vertical from the substrate, and a compositional gradient of at least one chemical element of the silicon oxycarbide within at least a portion of the thickness extending vertical; and 
 at least one inorganic coating of a ceramic, wherein the ceramic is one or more refractory oxides selected from the group of zirconia, alumina, and yttrium-stabilized zirconium (YSZ), molybdenum disulfide (MoS 2 ), MCrAIY, wherein M is Co, Ni or Co/Ni, or a combination thereof, the at least one inorganic ceramic coating being at least partially embedded in or infused with the interlayer. 
 
     
     
       2. The composite of  claim 1 , wherein the reinforced organic polymer matrix is a fiber reinforced polymer chosen from carbon fiber reinforced polymer, glass fiber reinforced polymer, carbon nanotube reinforced polymer, Kevlar (poly-paraphenylene terephthalamide) fiber reinforced polymer, or ceramic fiber reinforced polymer. 
     
     
       3. The composite of  claim 1 , wherein the interlayer consists essentially of silicon oxycarbide. 
     
     
       4. The composite of  claim 1 , wherein the at least one chemical element is oxygen, carbon, nitrogen, sulfur, or halogen. 
     
     
       5. The composite of  claim 1 , wherein the compositional gradient comprises a varying concentration of the at least one element within the thickness. 
     
     
       6. The composite of  claim 1 , wherein the varying concentration comprises a carbon-rich interlayer portion in proximity to the substrate and an oxygen-rich, or nitrogen-rich, or nitride-rich interlayer portion in proximity to the inorganic coating. 
     
     
       7. The composite of  claim 1 , wherein the concentration gradient of the at least one chemical element is essentially linear within the thickness of the interlayer, is essentially step-wise within the thickness of the interlayer, or is a plurality of concentration gradients within the thickness of the interlayer. 
     
     
       8. A method for providing a coated polymeric composite substrate comprising:
 (i) depositing, on a polymeric composite substrate surface, by a vapor deposition process, a sputtering process or a plasma enhanced chemical vapor deposition process, a thickness of an interlayer, the interlayer comprising silicon oxycarbide and having a varying concentration gradient of at least one chemical element of the silicon oxycarbide within at least a portion of the thickness; 
 (ii) depositing, into at least a portion of the interlayer, via a kinetically driven thermal spray process, inorganic material of a ceramic such that the inorganic material is at least partially embedded in or infused with the interlayer, wherein the ceramic is one or more refractory oxides selected from the group of zirconia, alumina, and yttrium-stabilized zirconium (YSZ), molybdenum disulfide (MoS 2 ), MCrAIY, wherein M is Co, Ni or Co/Ni, or a combination thereof; and 
 (iii) forming a coating of the inorganic material on at least a portion of the interlayer; 
 wherein the kinetically driven thermal spray process is exclusive of the vapor deposition process, the sputtering process or the plasma enhanced chemical vapor deposition process of step (i). 
 
     
     
       9. The method of  claim 8 , further comprising eliminating or reducing chemical or physical alteration to at least a portion of the composite substrate by the high temperature and/or kinetic inorganic particles. 
     
     
       10. The method of  claim 8 , wherein the polymeric composite is a fiber reinforced organic polymer matrix chosen from carbon fiber reinforced polymer, glass fiber reinforced polymer, carbon nanotube reinforced polymer, Kevlar (poly-paraphenylene terephthalamide) fiber reinforced polymer or ceramic fiber reinforced polymer. 
     
     
       11. The method of  claim 8 , wherein the interlayer consists essentially of silicon oxycarbide. 
     
     
       12. The method of  claim 8 , wherein the interlayer is deposited by a vapor phase deposition technique, a sputtering technique, or plasma deposition technique, or combinations thereof. 
     
     
       13. An article comprising:
 a fiber reinforced organic polymer composite substrate; 
 a thickness of an interlayer consisting essentially of silicon oxy-carbide directly on the composite substrate, the interlayer having a concentration gradient of at least one chemical element of the silicon oxy-carbide within at least a portion of the thickness of the interlayer and the interlayer having an inverse relationship of a concentration of the carbon to the oxygen in a least a portion of the thickness of the interlayer; and 
 an inorganic coating of a ceramic embedded in or infused with the interlayer as the result of a kinetic thermal spray process, wherein the ceramic is one or more refractory oxides selected from the group of zirconia, alumina, and yttrium-stabilized zirconium (YSZ), molybdenum disulfide (MoS 2 ), or MCrAlY, wherein M is Co, Ni or Co/Ni, or combination thereof, the ceramic, the molybdenum disulfide (MoS 2 ), or the MCrAlY providing one or more of anti-wear, anti-abrasion, anti-corrosion, restorative, electrical and/or thermal conductance, and anti-friction properties to the composite substrate. 
 
     
     
       14. The article of  claim 13 , wherein the article is a component of a vehicle, an aerospace vehicle, watercraft, or construction element.